Skip to main content
Log in

Development of a microchannel catalytic reactor system

  • Journal Review
  • Published:
Korean Journal of Chemical Engineering Aims and scope Submit manuscript

Abstract

The purpose of this article is to demonstrate the applicability of microreactors for use in catalytic reactions at elevated temperatures. Microchannels were fabricated on both sides of a silicon wafer by wet chemical etching after pattern transfer using a negative photoresist. The walls of the reactor channel were coated with a platinum layer, for use as a sample catalyst, by sputtering. A heating element was installed in the channel on the opposite surface of the reactor channel. The reactor channel was sealed gas-tight with a glass plate by using an anodic bonding technique. A small-scale palladium membrane was also prepared on the surface of a 50-Μm thick copper film. In the membrane preparation, a negative photoresist was spin-coated and solidified to serve as a protective film. A palladium layer was then electrodeposited on the other uncovered surface. After the protective film was removed, the resist was again spin-coated on the copper surface, and a pattern of microslits was transferred by photolithography. After development, the microslits were electrolitically etched away, resulting in the formation of a palladium membrane as an assemblage of thin layers formed in the microslits. The integration of the microreactor and the membrane is currently under way.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  • Bums, J. R. and Ramshaw, C.,“Development of a Microreactor for Chemical Production,,”Trans IChem E.,77,206 (1999).

    Article  Google Scholar 

  • Chambers, R. D., Hutchinson, J. and Sandford, G.,“Recent Studies at Durham on Direct Fluorination,,”J. Fluorine Chem.,100,63 (1999).

    Article  CAS  Google Scholar 

  • Chambers, R. D. and Spink, R. C. H.,“Microreactors for Elemental Fluorine,,”Chem. Commun., 883 (1999).

  • Cui, T., Fang, J., Zheng, A., Jones, F. and Reppond, A.,“Fabrication of Microreactors for Dehydrogenation of Cyclohexane to Benzene,,”Sensors and Actuators B,71,228 (2000).

    Article  Google Scholar 

  • Ehrfeld, W.,“Microreaction Technology, Industrial Prospects,,” Springer, Berlin, Germany (2000).

    Google Scholar 

  • Ehrfeld, W., Hessel, V. and Löwe, H.,“Microreactors,,” Wiley-VCH, Weinheim Germany (2000).

    Google Scholar 

  • Fletcher, P. and Haswell, S.,“Downsizing Synthesis,,”Chemistry in Britain,35,38(1999).

    CAS  Google Scholar 

  • Franz, A. I, Ajmera, S. A., Firebaugh, S. L., Jensen, K. F. and Schmidt, M. A.,“Expansion of Microreactor Capabilities through Improved Thermal Management and Catalyst Deposition,,” Microreaction Technology, Industrial Prospects, Ed. W. Ehrfeld, Springer, Berlin, 197 (2000).

    Google Scholar 

  • Freemantle, M.,“Downsizing Chemistry,,”Chem. Eng. News,22, 27 (1999).

    Google Scholar 

  • Greenway, G. M., Haswell, S. J., Morgan, D. O., Skelton, V. and Styring, P.,“The Use of a Novel Microreactor for High Throughput Continuous Flow Organic Synthesis,,”Sensor and Actuators B,63, 153 (2000).

    Article  Google Scholar 

  • Hessel, V., Ehrfeld, W., Golbig, K., Hofmann, C., Jungwirth, St., Löwe, H., Richter, Th., Storz, M., Wolf, A, Wörz, O. and Breysse, J.,“High Temperature HCN Generation in an Integrated Microreaction System,,” Microreaction Technology, Industrial Prospects, Ed. W. Ehrfeld, Springer, Berlin, 151 (2000).

    Google Scholar 

  • Haswell, S. J. and Skelton, V.,“Chemical and Biochemical Microreactors,,”Trends in Anal. Chem.,19, 389 (2000).

    Article  CAS  Google Scholar 

  • Hsing, I. M., Srinivasan, R., Harold, M. P., Jensen, K. F. and Schmidt, M. A.,“Simulation of Micromachined Chemical Reactors for Heterogeneous Partial Oxidation Reactions,,”Chem. Eng. Sci.,55, 3 (2000).

    Article  Google Scholar 

  • JÄhnisch, K., Baerns, M., Hessel, V., Ehrfeld, W., Haverkamp, V., Löwe, H., Wille, Ch. and Guber, A.,“Direct Fluorination of Toluene Using Elemental Fluorine in Gas/Liquid Microreactors,,”J. Fluorine Chem.,105,117 (2000).

    Article  Google Scholar 

  • Janicke, M. T., Kestenbaum, H., Hagendorf, U., Schüth, F., Fichtner, M. and Schubert, K.,“The Controlled Oxidation of Hydrogen from an Explosive Mixture of Gases Using a Microstructured Reactor/ Heat Exchanger and Pt/Al2O3 Catalyst,,”J. Catalysis,191, 282 (2000).

    Article  CAS  Google Scholar 

  • Jensen, K. E,“Microreaction Engineering -is small better?,,”Chem. Eng. Sci.,56, 293 (2001).

    Article  CAS  Google Scholar 

  • Kestenbaum, H., de Oliveria, A. L., Schmidt, W., Schüth, F., Ehrfeld, W., Gebauer, K., Löwe, H. and Richter, Th.,“Synthesis of Ethylene Oxide in a Microreaction System,” Microreaction Technology, Industrial Prospects, Ed. W. Ehrfeld, Springer, Berlin, 207 (2000).

    Google Scholar 

  • Kursawe, A., Dietzsch, E., Kah, S., Hönicke, D., Fichtner, M., Schubert, K. and WieΒmeier, G.,“Selective Reactions in Microchannel Reactors,” Microreaction Technology, Industrial Prospects, Ed. W. Ehrfeld, Springer, Berlin, 213 (2000).

    Google Scholar 

  • Kusakabe, K., Miyagawa, D., Gu, Y., Maeda, H. and Morooka, S., “Development of a Self-Heating Microreactor for Catalytic Reactions,”J. Chem. Eng. Japan (2001a),34,441 (2001b).

    Article  CAS  Google Scholar 

  • Kusakabe, K., Takahashi, M., Maeda, H. and Morooka, S.,“Preparation of Thin Palladium Membranes by a Novel Method Based on Photolithography and Electrolysis”J. Chem. Eng. Japan (2001b) in press.

  • Lee, A., Tonkovich, Y., Fitzgerald, S. P., Zilka, J. L., LaMont, M. J., Wang, Y., VanderWiel, D. P. and Wegeng, R. S.,“Microchannel Chemical Reactors for Fuel Processing Applications. II. Compact Fuel Vaporization” Microreaction Technology, Industrial Prospects, Ed. W. Ehrfeld, Springer, Berlin, 364 (2000).

    Google Scholar 

  • Lerou, J. J. and Ng, K. M.,“Chemical Reaction Engineering: A Multiscale Approach to a Multiobjective Task”Chem. Eng. Sci.,51, 1595 (1996).

    Article  CAS  Google Scholar 

  • Liauw, M. A., Baerns, M., Broucek, R., Buyevskaya, O. V., Commenge, J.-M., Corriou, J.-P., Falk, L., Gebauer, K., Hefter, H. J., Langer, O.-U., Löwe, H., Matlosz, M., Renken, A., Rouge, A., Schenk, R., Steinfeldt, N. and Walter, St., “Periodic Operation in Microchannel Reactors” Microreaction Technology, Industrial Prospects, Ed. W. Ehrfeld, Springer, Berlin, 224 (2000).

    Google Scholar 

  • Losey, M. W., Schmidt, M. A. and Jensen, K. E.,“A Micro Packed-Bed Reactor for Chemical Synthesis” Microreaction Technology, Industrial Prospects, Ed. W. Ehrfeld, Springer, Berlin, 277 (2000).

    Google Scholar 

  • Löwe, H. and Ehrfeld, W.,“State-of-the-Art in Microreaction Technology: Concepts, Manufacturing and Applications”Electrochim. Acta,44,3679 (1999).

    Article  Google Scholar 

  • Martin, P. M., Matson, D. W. and Bennett, W. D.,“Microfabrication Methods for Microchannel Reactors and Separation Systems”Chem. Eng. Comm.,173, 245 (1999).

    Article  CAS  Google Scholar 

  • Mayer, J., Fichtner, M., Wolf, D. and Schubert, K.,“A Microstructured Reactor for the Catalytic Partial Oxidation of Methane to Syngas” Microreaction Technology, Industrial Prospects, Ed. W. Ehrfeld, Springer, Berlin, 187 (2000).

    Google Scholar 

  • Mex, L. and Müller, J.,“Miniaturised Direct Methanol Fuel Cell with a Plasma Polymerised Electrolyte Membrane” Microreaction Technology, Industrial Prospects, Ed. W. Ehrfeld, Springer, Berlin, 402 (2000).

    Google Scholar 

  • Morooka, S., Yan, S., Yokoyama, S. and Kusakabe, K.,“Palladium Membrane Formed in Macropores of Support Tube by Chemical Vapor Deposition with Crossflow through a Porous Wall”Sep. Sci. Technol.,30, 2877 (1995).

    Article  CAS  Google Scholar 

  • Quiram, D. J., Hsing, I.-M., Franz, A. J., Jensen, K. F. and Schmidt, M. A.,“Design Issues for Membrane-based, Gas Phase Microchemical Systems,”Chem. Eng. Sci.,55,3065 (2000).

    Article  CAS  Google Scholar 

  • Sadykov, V. A., Pavlova, S. N., Saputina, N. F., Zolotarskii, I. A., Pakhomov, N. A., Moroz, E. M., Kuzmin, V. A. and Kalinkin, A. V., “Oxidative Dehydrogenation of Propane over Monoliths at Short Contact Times,”Catalyst Today,61, 93 (2000).

    Article  CAS  Google Scholar 

  • Srinivasan, R., Hsing, I.-M., Berger, P. E., Jensen, K. F, Firebaugh, S. L., Schmidt, M. A., Harold, M. P., Lerou, J. J. and Ryley, J. F,“Micromachined Reactors for Catalytic Partial Oxidation Reactions”AIChE J.,43, 3059 (1997).

    Article  CAS  Google Scholar 

  • Stepánek, F., Kubícek, M., Marek, M. and Adler, P M.,“Optimal Design and Operation of a Separating Microreactor”Chem. Eng. Sci.,54,1493 (1999).

    Article  Google Scholar 

  • Tsubota, T., Miyagawa, D., Kusakabe, K. and Morooka, S.,“Preparation of a Catalytic Reactor Composed of a Microchannel Etched on a Silicon Wafer,”Kagaku Kogaku Ronbunshu,26, 895 (2000).

    CAS  Google Scholar 

  • Wilson, N. G. and McCreedy, T.,“On-Chip Catalysis Using a Lithographically Fabricated Glass Microreactor the Dehydration of Alcohols Using Sulfated Zirconia,”Chem. Commun., 733 (2000).

  • Wörz, O., JÄckel, K. P., Richter, Th. and Wolf, A.,“Microreactors, a New Efficient Tool for Optimum Reactor Design,”Chem. Eng. Sci.,56,1029 (2001).

    Article  Google Scholar 

  • Yan, S., Maeda, H., Kusakabe, K. and Morooka, S.,“Thin Palladium Membrane Formed in Support Pores by Metal-Organic Chemical Vapor Deposition Method and Application to Hydrogen Separation,”Ind. Eng. Chem. Res.,33, 616 (1994).

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Shigeharu Morooka.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Kusakabe, K., Morooka, S. & Maeda, H. Development of a microchannel catalytic reactor system. Korean J. Chem. Eng. 18, 271–276 (2001). https://doi.org/10.1007/BF02699164

Download citation

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF02699164

Key words

Navigation